US6202381B1 - Method for reconfiguring a wall panel system - Google Patents

Abstract

A wall panel including a rectangular frame, a pair of wall members and a thin decorative sheet covering the wall members. The frames includes two spaced apart, generally parallel vertical frame members and spaced apart, generally parallel horizontal lower and upper frame members. The horizontal frame members are connected to the vertical frame members at opposite ends thereof to form the rectangular frame. Each of the frame members includes a core member and a pair of sidewall members attached to opposite sides of the core member. The wall members are attached to the sidewalls on opposing sides of the frame members. A decorative sheet covers the outer surface of each wall member. A method for manufacturing the frame members includes providing a fixture with spaced apart first, second and third surfaces. A hanger bracket is mounted to the vertical frame core member and is positioned in the fixture such that the hanger bracket engages the first surface. The sidewalls are positioned on opposite sides of the core in the fixture and engage the second surface. The sidewalls are attached to the core member. A method for making the panel includes providing a fixture. The frame members are inserted in the fixture so that each one engages a fixture surface. A wall member is mounted on each side of the frame, with a filler member disposed inside the frame between the wall members.

Description

This application is a divisional of U.S. patent application Ser. No. 08/864,459, filed May 28, 1997, which claims the benefit of U.S. Provisional Application Ser. No. 60/018,956, filed Jun. 7, 1996, the entire disclosures of which are hereby incorporated herein by reference.

BACKGROUND OF THE INVENTION

The present invention relates generally to a wall panel system, and in particular, to an improved wall panel, components therefore and a method for making the all panel.

Panel systems are commonly used to divide large, open office space into separate work spaces. For example, Herman Miller. Inc., the assignee of the present application, manufacturers and sells two such work space management systems: the ACTION OFFICE® system and the ETHOSPACE® system. Often, wall panels arranged in such systems include an internal frame with a sheet of wall board or comparable material attached to the side of the frame. Typically, the frame is made from roll-formed or extruded metal, with the wall board adhesively secured to the side of the metal frame members. Each side of the wall panel usually is covered with a fabric that is either bonded to the frame, or attached with an elastic band, so as to provide an aesthetically pleasing appearance to the user.

Adjacent wall panels in the system typically are connected to one another with a variety of connector assemblies. For example, wall panels placed end-to-end commonly are connected to each other, while wall panels oriented perpendicular to each other in a two-way, three-way or four-way configuration typically are connected to a corner post located at the junction of the intersecting panels. Typically, a cover is attached to those sides of the corner post not connected to a wall panel so as to provide an aesthetically pleasing surface that matches the surface of the adjacent panels.

Wall panels often are provided with wire management capabilities, typically including horizontal wire channels positioned at the top and bottom of the panel. Wall panels may also include vertical channels, typically formed by the vertical frame members, that extend between the top and bottom of the panel. Typically, wall panels having a horizontal channel at the top of the panel also provide a top cap to cover the channel. When a corner post is interposed between panels, a cap also is installed on top of the corner post to provide a continuous, unbroken line across the top of a system of wall panels.

Wall panels may also include power distribution systems, whereby the wall panels can be electrically connected so as to provide the user with access to power in each work space created by the system of wall panels.

SUMMARY OF THE INVENTION

Briefly stated, one aspect of the invention is directed to an improved wall panel. The wall panel includes a rectangular frame, a pair of sheetlike wall members and two thin decorative sheets. The rectangular frame includes two spaced apart, and generally parallel vertical side frame members and spaced apart and generally parallel horizontal lower and upper frame members. The frame members are connected at opposite ends thereof to form the rectangular frame. Each of the frame members includes a core member and a pair of sidewall members attached to opposite sides of the core member. The sheetlike wall members, preferably made of fiberboard, have an inner surface attached to the side walls of each frame member. The thin decorative sheets, preferably cloth, cover the outer surface of the wall members on each side of the panel.

In a preferred embodiment, the sidewall members include a substantially flat leg portion having an inner surface attached to the core member and an outer surface attached to the wall member. The sidewall member includes an edge portion extending laterally outward from the leg portion. Preferably, the edge portion is configured as a C-shaped channel facing inwardly away from the wall panel surface. When the frame members are assembled into a rectangular frame, the edge portions extend around the periphery of the wall panel. The sidewalls, including the edge portions, form a shallow, recess on opposite sides of the panel. Each recess has a bottom surface defined by the outer surface of the leg portions. The wall members are received in the recesses on opposite sides of the panel.

In another aspect of the invention, a thin barrier sheet, or scrim, is disposed between the decorative sheet and the outer surface of the wall member as a fire blocking member. The barrier sheet preferably includes a thin aluminum foil layer laminated to a fiberglass layer.

The wall panel also includes an inner filler member disposed between the wall members. The filler member extends between the upper and lower horizontal frame members. Preferably, the inner surface of the wall members are attached to the filler member.

In a preferred embodiment of the invention, the sidewall members on the upper horizontal frame member extend upwardly from the upper core member to form a horizontal channel running substantially the length of the wall panel. The bottom of the channel is defined by the upper surface of the upper core member and the sides of the channel are defined by the upwardly extending sidewall members. A top cap is releasably secured to the upper frame member to cover the channel.

In one aspect of the invention, the wall panel also includes at least one vertical channel communicating with the upper horizontal channel and a bottom portion of the wall panel. Preferably, the vertical channel is defined by an inner surface of one of the vertical core members, a partition member spaced apart from the inner core surface of the vertical core member and the inner surface of the wall member. Preferably, the partition member extends between the inner surfaces of the opposing wall members and is attached to at least one of the wall members. The partition member also extends substantially between the upper and lower frame members.

In another aspect of the invention, a power distribution system is provided at the base of the Ball panel. The power distribution system includes a power distribution server, including a harness and a module receptacle, which is attached to a bottom of the lower frame member-. The power distribution system is adapted to be electrically connected with power distribution systems located in adjacent panels. In addition, an outlet box is attached to one of the inner surfaces of the wall members between the upper and lower frame members. The other wall member has an opening provided to allow access to the outlet box. The outlet box is electrically connected to the power distribution system with an electrical conduit disposed in the vertical channel.

In another aspect of the invention, a plastic strip is attached to the decorative sheet at each of its edges. The strip includes a first hook member that is adapted to engage the edge portion of the sidewall member. Preferably, the strip also includes a second hook member that is adapted to receive a tool member which can be used to stretch the decorative sheet between opposing frame members while simultaneously disposing the first hook member on the edge portion of the side wall.

In another aspect of the invention, wall panels placed end-to-end are attached using an upper and lower draw block that engage hanger brackets attached to the ends of the wall panels. A draw rod operably engages the draw blocks which pull the hanger brackets and corresponding panels together.

In yet another aspect of the invention, a corner post is provided for connecting two or more panels at 90°. The corner post includes an elongated tube having a pair of inwardly facing channels formed on each side of the tube. A plate member is secured inside each end of the tube; the upper plate having a threaded hole in the middle of the plate.

The corner post is provided with a height adjustable cap which includes a post member and a cover member supported by the post member. The post member threadably engages the hole in the upper plate and can be rotated to adjust the height of the cover. In this way, the cover can be raised or lowered to provide a smooth transition between adjacent wall panel top caps.

In another aspect of the invention, an outwardly facing groove is formed in each corner of the tube. A cover has diagonally oriented beaded portions. The cover is attached to the corner post by releasably engaging two of the corner grooves with the beaded portions. The post cover is used to cover those sides of the corner post not connected to a wall panel, thereby providing an aesthetically pleasing appearance.

In another aspect of the invention, a method is provided for manufacturing the vertical side frame members. In particular, the method includes providing a core member, a pair of sidewall members each having an edge portion, and a hanger bracket. The hanger bracket is attached to the core member. The core member and attached hanger bracket are then positioned in a fixture such that the hanger bracket engages a first surface of the fixture. The sidewall members are positioned in the fixture on both sides of the core member such that the edge portion of each sidewall member engages a second and third surface of the fixture, respectively, positioned predetermined distances from the first surface. The sidewall members are then attached to the core member.

A similar method is provided for making the upper and lower horizontal frame members, wherein the fixture surfaces are positioned to support the edge portion of the sidewall members and the outer surface of the core member.

A method also is provided for manufacturing the improved wall panel. In particular, one of the sheetlike wall members is placed in a fixture. The side frame members and upper and lower horizontal frame members also are positioned in the fixture. The wall member fills the recess formed by the sidewall members on one side of the rectangular frame. Adhesive is applied to one of the sidewall members and wall member before the frame is disposed on the wall member. Adhesive also is applied to both sides of the filler member. One or more partition members is adhesively attached to the inner surface of the wall member so as to form a vertical channel with the inner surface of one of the side core members. The filler member is inserted into the space formed by the frame members and the partition members. The second sheetlike wall member is then disposed in the recess on the opposite side of the frame. The wall members are attached to each frame member with mechanical fasteners. A decorative sheet and barrier sheet are secured over the outer surface of each wall member.

The present invention provides significant advantages over other wall panel systems and methods of manufacture. In particular, the three-piece frame member construction, i.e., a pair of sidewall members attached to a core member, yields a simple, inexpensive structural part that provides several advantages over roll-formed or extruded metal channels. By using a wood core member, the side wall members can be easily attached to the core with staples, rather than by welding or other more expensive methods of manufacture. Similarly, the wall members can be stapled directly to the frame members, as well as adhesively secured, so as to improve the strength of the panel. In addition, various accessories, such as the power distribution server, can be easily mounted to the bottom of the panel with wood fasteners, without providing mounting holes in the lower frame member. Moreover, the wood can be easily cut to length for each frame member, or shortened so as to provide access to the vertical channel, without wasting material or making complicated cuts or stampings in the sheet metal.

Also important, the three-piece frame member construction allows the manufacturer to provide precise dimensions between the outermost surface of the hanger bracket and the outermost surface of the side wall members. This dimension is critical when two panels are installed adjacent to each other. For example, when two panels are connected, the adjacent hanger brackets are pulled together by a wedge block, as explained below. When connected in this manner, the panel-to-panel interface, or joint between the panels, is defined by the distance between the adjacent outer surfaces of opposing edge portions covered with fabric. Thus, by maintaining the distance between the outer surface of the edge portion and the hanger bracket as a constant, the joints at each panel interface are kept constant, i.e., have the same gap between panels. Moreover, when a wall panel has a thicker fabric installed around the edge portions, the distance between the edge portion and hanger bracket can be increased so that the gap between panels, when connected, remains the same, regardless of the fabric thickness.

The vertical channel also provides significant advantages. For example, wires can be easily routed from the top of the panel to the bottom. The channel also provides ideal passage for the electrical conduit running from the outlet box installed inside the panel. In addition, because the channel is inside of the frame and adjacent to the box, rather than on the outside of the frame, the frame member does not have to be pierced in order to rout the wiring to the outlet box. Moreover, wires disposed in the channel are not exposed when the panels are disconnected and cannot therefore be caught or hooked by the panel-to-panel connectors.

The improved corner post also provides significant advantages over similar devices. For example, the corner post cover is height adjustable, so that it car, be adjusted to provide a continuous line across the top of a system of panels. Moreover, the grooves provided in the corner post tube provide a simple but efficient way to attach covers, whether they be flat, or formed at 90°. As such, the orientation of the tube is irrelevant to the placement of connecting panels and/or post covers. Because the tube is symmetrical, the cover and panels can be arranged in any configuration, without having to reorient the tube member.

Yet another significant advantage is the method of fabric attachment. In particular, the double-hook strip configuration allows an installer to use a tool to install the fabric. As such, the installer can apply a considerable force to tightly stretch the fabric between opposing frame members to thereby provide a smooth and pleasing appearance. Moreover, the releasable hook allows the user to easily replace the fabric if it becomes damaged or if a color change is desired. The new fabric can be installed quickly and easily without adhesives or difficult to install elastic bands that run around the periphery of the wall panel. Indeed, adjacent panels need not even by disconnected in order to install a new sheet of fabric, thereby avoiding the task of disassembling the panels.

Finally, the wall panel construction lends itself to improved manufacturability and overall quality. Most importantly, as described above, each frame member can be made with extremely tight tolerances so that the gap between panels is maintained as a constant when the wall panels are assembled as a system. Moreover, by locating the frame members to outside dimensions in the fixture, the overall panel construction is improved by providing extremely tight tolerances for the height and width of each panel. The improved quality associated with this method of manufacture in turn facilitates and cases installation of the panels while providing an improved overall look for the system.

The present invention, together with further objects and advantages, will be best understood by reference to the following detailed description taken in conjunction with the accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is an exploded perspective view of the wall panel.

FIG. 2 is an exploded perspective view of the wall panel with a top cap, base cover and power distribution system.

FIG. 3 is an exploded view of a wall panel end cover.

FIG. 4 is an exploded view of a corner post configuration.

FIG. 5 is an exploded view of an alternative embodiment of a corner post configuration.

FIG. 6 is an enlarged perspective view of a panel-to-panel light seal.

FIG. 7 is an enlarged exploded view of a corner post cap.

FIG. 8 is a side view of a wall panel.

FIG. 9 is an end view of a wall panel with the power distribution server omitted.

FIG. 10 is a cross-sectional view of the wall panel taken alongline10—10 of FIG.8.

FIG. 11 is a cross-sectional view of the wall panel taken alongline11—11 of FIG.8.

FIG. 12 is a bottom view of the wall panel taken alongline12—12 of FIG. 8, with the power distribution server omitted.

FIG. 13 is a perspective view of the power distribution bracket.

FIG. 14 is a cross-sectional view of the wall panel taken alongline14—14 of FIG. 8 with the power distribution server not shown.

FIG. 15 is a cross-sectional view of the wall panel taken alongline15—15 of FIG.8.

FIG. 16 is a cross-sectional view of the wall panel taken alongline16—16 of FIG.8.

FIG. 17 is a cross-sectional view of the wall panel taken alongline17—17 of FIG.8.

FIG. 18 is a partial perspective view of the top cap.

FIG. 19 is an exploded perspective view of two wall panels placed end-to-end without the fabric installed.

FIG. 20 is a side view of two wall panels connected together without the fabric installed.

FIG. 21 is a side view of the fabric sheet.

FIG. 22 is a cross-section of the strip attached to the fabric.

FIG. 23 is a cross-section of an alternative embodiment of the strip attached to the fabric.

FIG. 24 is a side view of the inside corner of the upper horizontal channel.

FIG. 25 is a perspective view of the power distribution server.

FIG. 26A is a top view of a wall panel junction showing a three-way connection of power distribution servers located in the adjacent wall panels.

FIG. 26B is a top view of a wall panel junction showing a two-way connection of power distribution servers located in the adjacent wall panels.

FIG. 26C is a top view of a wall panel junction showing a four-way connection of power distribution servers located in the adjacent wall panels.

FIG. 27 is a top view of the power distribution server.

FIG. 28 is a perspective view of the upper and lower draw blocks.

FIG. 29 is a perspective view of an alternative configuration of the upper and lower draw blocks.

FIG. 30 is a perspective view of an alternative configuration of the upper and lower draw blocks.

FIG. 31 is a side view of two wall panels connected to a corner post.

FIG. 32 is a top cross-sectional view of three wall panels connected to a corner post.

FIG. 33 is a top cross-sectional view of two wall panels connected to a corner post.

FIG. 34 is a perspective view of a corner post base cover.

FIG. 35 is a perspective view of a draw rod and draw blocks engaging a corner post.

FIG. 36 is a perspective view of a draw rod with a partial end cover.

FIG. 37 is a side view of a draw rod and draw blocks engaging a corner post.

FIG. 38 is an exploded side view of different height wall panels with a draw rod and draw blocks interposed between the panels.

FIG. 39 is a partial inner perspective view of a draw rod with a partial end cover.

FIG. 40 is a partial outer perspective view of a draw rod with a partial end cover.

FIG. 41 is an exploded perspective view of a hanger bracket mounted on a permanent wall.

FIG. 42 is a partial cross-sectional view of the hanger bracket mounted on a permanent wall.

FIG. 43 is a perspective view of a brace member installed on a wall panel.

FIG. 44 is a side view of a brace member installed on a wall panel.

FIG. 45 is a perspective view of a brace member.

FIG. 46 is a perspective view of a fabric installation tool.

FIG. 47 is a top view of the fabric installation tool engaging a fabric sheet on a wall panel.

FIG. 47A is an partial enlarged view of an installation tool with an alternative blade configuration.

FIG. 48 is a perspective view of an alternative embodiment of the fabric installation tool.

FIG. 49 is a top view of the fabric installation tool of FIG. 44 engaging a fabric sheet on a wall panel.

FIG. 50 is a perspective view of a vertical side frame member tool fixture.

FIG. 51 is an end view of the side frame tool fixture with a side frame member installed therein.

FIG. 52 is a schematic of an automated took fixture for assembling the side frame member.

FIG. 53 is a perspective view of a upper and lower frame member tool fixture.

FIG. 54 is an end view of the upper frame tool fixture with an upper frame member installed therein.

FIG. 55 is a perspective view of the wall panel assembly fixture.

FIG. 56 is a side view of a dual staple gun engaging a wall panel installed in the wall panel assembly fixture.

FIG. 57 is a perspective view of a end cover support bracket.

FIG. 58 is an end view of a wall panel with a power distribution server attached to the bottom of the wall panel as taken alongline58—58 of FIG.31.

FIG. 59 is a bottom perspective exploded view of a wall panel and power distribution server.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

Referring to the drawings, FIG. 1 shows animproved wall panel10 including arectangular frame12, a pair ofsheetlike wall members120 and a pair of thindecorative sheets130. Theframe12 includes two spaced apart, and generally parallel verticalside frame members14 and spaced apart and generally parallel horizontal lower andupper frame members18,16.

Eachframe member14,16,18 includes anelongated core member28,30,32 and a pair ofelongated sidewall members34,36,38. Preferably, the core member is made of wood. As used herein, the terms “wood” and “wooden” are intended to have relatively broad meanings, including but not limited to, solid wood and wood products, such as particle board, fiber board and laminated strand lumber. Most preferably, theside core members28 are made of laminated strand lumber, such as the 38# density material available from TrusJoist/MacMillan Ltd. Partnership in Deerwood, Minn. Thehorizontal core members30,32 preferably are made of 45# density particle board. Alternatively, other materials, such as foamed polymers or composites, may be used.

Eachsidewall member34,36,38 includes a substantiallyflat leg portion42,54,56 andedge portion40,58,60 respectively. Theedge portion40,58,60 extends laterally outward from theleg portion42,54,56. Preferably, the sidewall members are made from 12 gauge steel sheet metal and are roll formed. However, it should be understood that other materials, such as plastic could also be used. Each leg portion has an inner44,45,43 andouter surface46,47,49; theinner surface44,45,43 engages the side surface of the core member. Preferably, theinner surface44,45,43 is mechanically fastened to theside52,53,57 of the core member, for example, by usingstaples700, as shown in FIG.16. Alternatively, adhesive, nails, rivets or screws can be used to secure the sidewall member to the core member.

As shown in FIG. 1, thesidewall members34 of each vertical frame member include anend portion68 that extends upwardly past thetop end20 of theside core member28 along the longitudinal direction of thevertical frame member14. The upwardly extendingend portions68 of thesidewall members34 overlap thesidewall members36 of theupper frame member18, which includeleg portions54 that extend upwardly from the upperframe core member30. Each end of the upper framemember sidewall members36 includes aflange portion580 stepped inwardly from theleg portion54, as shown in FIGS. 1 and 2. Theflange portion580 extends from and is integrally formed with the leg portion. The upwardly extendingend portions68 overlap and are attached to the corresponding steppedflange portions580 and thewall member120, preferably with mechanical fasteners. Because theflanged portion580 is stepped inwardly, theouter surfaces46,49 are flush. Theedge portion58 of the upper frame member and theedge portion40 of the vertical frame are mitered at approximately 45° at the point of intersection in order to form a corner.

As shown in FIGS. 1,2,9 and10, anelongated hanger bracket70 is mounted to theouter surface50 of each vertical core member. Thehanger bracket70 includes two spaced apart, inwardly facingchannels72 connected by abridge portion74 that is fastened to thecore28, preferably with a plurality offasteners540.Fasteners542 also secure each end of eachchannel72 to thecore member28. Eachchannel72 has aninner leg76, anouter leg78 and anouter surface member82. Theinner legs76 of the channels and thebridge portion74 form an outwardly facingchannel300. Theoutermost corners84 on each bracket, formed by the intersection of the outer leg and the surface member, have a plurality ofslots86 running the length of the hanger bracket. Theouter surface member82 of the inwardly facingchannels72 defines the outermost surface of each end of the wall panel. Theslots86 in the hanger bracket are adapted to receive and support various components attached to the wall panel. For example, overhead units and worksurface bracket supports, not shown in the Figures, typically engage the wall panel at the slots. For example, a cantilever bracket assembly adapted to engage the hanger bracket is described in U.S. Provisional Application Ser. No. 60/019,285, entitled CANTILEVER BRACKET ASSEMBLY and filed Jun. 7, 1996, the disclosure of which is hereby incorporated by reference.

As shown in FIGS. 2,8,9 and44, theinner surface43 of the upwardly extendingsidewalls36 on the upper frame member and theouter surface62 of theupper core member30 form ahorizontal channel88 which runs the width of the panel. At each end of the wall panel, theupper end20 of the verticalside core member28 lies substantially flush with, or slightly higher than, theouter surface62 of theupper core member30 so that wires, cables and the like can be passed easily from one panel to the next. In this way, theupper end20 of thevertical core member28 helps to define a portion of the bottom of thehorizontal channel88.

As shown in FIGS. 43-45, abrace member92 can be mounted at each end of the channel to provide additional support for the panel. Thebrace member92 includes a pair ofsidewall members94 disposed along theinner surface45 of the sidewall members. Thebrace member92 also includes abottom plate97 attached to theend20 of the core member and asecond bottom plate96 attached to theouter surface62 of theupper core member30. It should be understood that the sidewall members can also be attached to the wall members. Anopening95 is provided between the plates to provide access to avertical channel108. Thebrace member92 provides additional support for loads applied laterally to the top or side of the panel. In particular, the brace member helps distribute the load between opposing wall members, the upper frame member and the vertical frame member.

As shown in FIGS. 2,16 and18, the top portion of each sidewall leg portion on the upper frame members includes an inwardly facingridge98 that runs substantially the length of theupper frame member18.Intermittent openings100 are provided along the top portion. The openings are provided to locate the sidewalls in various tool fixtures during the assembly of the frames and wall panel.

Atop cap110 is attached to theupper frame member18. Thetop cap110 includes a pair of downwardly facingflanges112 that have a ribbedportion114 running the length of the flanges. Theribbed portion114 engages theridge98 formed on the inside of each sidewall member and releasably secures the top cap to the upper frame member. Each of theflanges112 also includes anedge portion113 that is angled inwardly from the ribbedportion114. Theedge portion113 facilitates installation of the top cap by engaging the ridges on the upper frame member as the top cap is first inserted into thechannel88. As thetop cap110 is pushed downwardly, theedge portions113 slide along the ridge so that the flanges are biased inwardly until the ribbed portion engages the ribbedportion114. Theflanges112 then spring back to their original position, as the ribbed portion releasably locks the top cap to the upper frame member. In this way, thetop cap110 covers and encloses thechannel88.

In a preferred embodiment, theends102 of the upper core member are spaced apart from theends104 of the vertical core member to form anopening106 between the members near each end of the panel as shown in FIG.17. Theseopenings106 provide access to avertical channel108, or tube, that extends between the upperhorizontal channel88 and the bottom of the wall panel, as shown in FIGS. 2,8,10, and11. Eachvertical channel108 is formed and defined by theinner surface48 of the vertical core member, apartition member140 that extends between the upper and lowerhorizontal frame members16,18 and theinner surface122 of thewall member120.

The ends103 of the lower horizontal core member are spaced apart from thelower end105 of the vertical core members so as to provide access to thevertical channel108 from the bottom of the panel as shown in FIG.12. In addition, thesidewall members38 on the lower frame member extend outwardly past theend103 of the core member along the longitudinal direction of the frame member, as shown in FIG.1. Thesidewalls34 are cut away at thelower end105 of the vertical side core member to provide an exposedportion550 of the side core member. The outwardly extendingbottom sidewall members38 overlap the exposed portion, and lie flush with the side frame sidewalls34. Theedge portions60,40 intersect and are mitered at approximately 45° to form a corner. Thelower core member32 also includes agroove33 running the length of the core member along the middle of theouter surface66.

As shown in FIG. 10,14 and16, theedge portions40,58,60 of each sidewall member are preferably configured as a C-shaped channel that runs the length of each side wall member. When the frame members are connected, theedge portions40,58,60 run substantially around the entire periphery on each side of the panel. Each channel includes aninner leg116 that extends laterally outward in a perpendicular relationship from the leg portion and anouter leg118 that defines the outer peripheral edge of the wall panel. Aintermediate surface member124 connects the inner116 andouter leg118. Thesurface member124 is in substantially the same plane as theouter surface126 of the wall member as shown in FIGS. 14-16. Theinner leg116 of the edge portion and theouter surface46,47,49 of thesidewall leg portions42,54,56 define a shallow, outwardly facing recess on each side of the frame. The recess is shaped to receive thesheetlike wall member120. Preferably, thewall member120 substantially fills the recess and is bounded around its periphery by theinner legs116 of the side walls.

As just described, each wall member is attached to one side of the frame withstaples702, as shown in FIG.16. The wall members stabilize and strengthen the wall panel. Preferably, thewall member120 is made of ½ inch thick fiberboard, such as the industrial insulation board available from Masonite in Lisbon Falls, Me., which is sanded, ironed and sealed. Preferably, thewall member120 is tackable, so that a user can attach various items to the wall member with tacks, or the like. Other materials, such as particle board or mineral board are also acceptable. Preferably, thewall member120 is both adhesively secured to theouter surface46,47,49 of the sidewalls and is mechanically fastened to thecore members34,36,38 through the sidewall members, preferably by stapling. The overlapping portions of thesidewall members34,36 of the vertical frame and the upper frame members are mechanically fastened to each other and to thewall member120 from the inside out, preferably withscrews121 as described above and shown in FIGS. 1,2 and8.

As shown in FIGS. 1,8 and10-11, afiller member150 is installed inside therectangular frame12. Thefiller member150 is disposed between thewall members120 and each side of the frame, and extends between the upper and lowerhorizontal frame members16,18. In a preferred embodiment, thefiller member150 is a honeycomb structure made from corrugated cardboard. The honeycomb is adhesively secured to theinner surface122 of each wall member. The honeycomb increases the strength of the panel and provides sound dampening for the panel. Preferably, the honeycomb filler member is bounded along each vertical end by thepartition members140 installed to form thevertical channels108. In this way, the vertical channels are separated from the honeycomb filler member.

Thepartition member140 includes a mountingflange142 and aboundary flange144 as shown in FIG.1. Referring to FIGS. 10 and 11, the mountingflange142 is adhesively bonded to theinner surface122 of one of thewall members120. Theboundary flange144 extends between the twowall members120 and can be attached to the side of the honeycomb filler member.

Referring to FIGS. 1 and 2, athin barrier sheet530, or scrim, is disposed between thedecorative sheet130 and thewall member120. Thebarrier sheet530 preferably includes a layer of aluminum foil laminated to a thin layer of fiberglass. Thebarrier sheet530 is preferably about 0.005 inches thick and is used as a fire blocking material. A commercially available barrier sheet is the MAANNIGLAS 1207® wet-lay glass fiber mat produced by Lydall Corporation. The barrier sheet can be attached to the wall member with adhesive or mechanical fasteners. Alternatively, the barrier sheet can wrap around the outer leg of the edge portion beneath the decorative sheet, which is attached to the leg with a strip member as described below.

Referring to FIGS. 1 and 2, each thindecorative sheet130 is disposed over one of theouter surfaces126 of the wall members. The decorative sheet is preferably a cloth fabric, although it should be understood that other flexible materials would be suitable for covering the wall panel. Referring to FIGS. 10,14,15 and16, the sheet is wrapped around theedge portion40,58,60 of each sidewall member and is attached to the outer le(118 of the edge portion. Preferably, astrip160 is attached to eachedge132 of the sheet. The strip may be sewn to the sheet or adhesively bonded. For example, as show in FIGS. 21-23, the strip is attached with a double-sided tape162 and sewn to the sheet.

Referring to FIGS. 21 and 23, thestrip160, preferably made from plastic, includes afirst hook member164 adapted to engage theouter leg118. Thestrip160 is attached to theouter surface136 of thefabric sheet130 so that thefirst hook member164 faces outwardly towards the edge of the fabric. Before installing the fabric, however, the fabric is folded over as shown in FIGS. 22-23 so that thestrip160 is positioned along theinner surface134 of the fabric and so that thefirst hook164 faces inwardly away from the foldededge133 of the fabric. Thefirst hook member164 is disposed on theouter leg118 of the edge portion of the sidewall member as shown in FIGS. 14-16.

Excess portions of the decorative sheet, or fabric, extend outwardly from each corner of the fabric sheet between the ends of the adjacent strip members to form acorner patch138 of material as shown in FIG.21. Thecorner patch138 is tucked inside the eight corners formed by theedge portion channels40,58,60 of the vertical, upper and lower frame members as the first hook member is installed on the outer leg of each channel. As shown in FIG. 24, aflexible corner block146 is inserted into intersectingchannels40,58 at one of the upper corners to hold the excess fabric, orcorner patch138, in the channels. Preferably, thecorner block146 is made of foam, although other resilient and flexible materials, such as rubber, may also be used. By tucking the excess fabric, orcorner patch138, into thechannels40,58, the exterior, exposedcorner148 of the wall panel is covered and provided with an aesthetically pleasing appearance.

In a preferred embodiment, thestrip160 also includes asecond hook member166. In one embodiment, shown in FIG. 23, thesecond hook member166 is positioned opposite of thefirst hook164 and faces the same direction as the first hook member, i.e., opens inwardly away from the foldededge133 of the fabric when it is folded over on itself. In a second embodiment, shown in FIG. 22, thesecond hook168 is positioned at the end of the strip and opens outwardly away from theouter surface136 of the fabric. In either embodiment, thesecond hook member166,168 is adapted to allow an installer to stretch tightly thefabric130 while installing thefirst hook164 on theouter leg118 of the sidewall member.

To facilitate the installation of thefabric130, atool170 is provided. Thetool170 includes amounting block171, ablade172, ahandle174 and ahousing176 as shown in FIGS. 46-47. The mountingblock171 is mounted to the housing and includes alip portion173 adapted to engage thesecond hook168, and aguide member175 configured as a hook that is adapted to be disposed around the end of the strip andfirst hook164. The tool also includes a plurality ofwheels180,181 rotatably mounted to thehousing176 and adapted to rotatably engage the side of the wall panel as the tool is moved around the periphery of the panel while engaging thestrip160.

To install the sheet of fabric, at least oneedge132 is installed by disposing thefirst hook164 on one of the sidewall memberouter legs118 as shown in FIGS. 14-16. The installer then engages the fabric with the tool by inserting thelip portion173 in one of thesecond hooks166,168 on one of the remaining strips, as shown in FIG. 47, and moves the tool along the edge of the wall panel. As the tool moves along the edge of the panel, thelip portion173, which is inserted into thesecond hook168 as theguide member175 encircles the end of the strip, pulls the strip inwardly so that thefirst hook164 can be inserted onto theouter leg118 as the end of the strip and first hook passes through the space between the core member, or hanger bracket, and the free edge of theouter leg118. Theblade172 includes anedge180 that is adapted to engage the strip and force the hook member past the outer leg. Thus, the installer uses thetool170 to stretch thefabric130 and force thefirst hook164 of the strip past the end portion and dispose it on theouter leg118. It should be understood that various tool configurations would work equally well for stretching and mounting the fabric sheet.

In another embodiment, the tool includes asecond blade member710 having anedge602, as shown in FIG.47A. Theblade member710 is adapted to engage the second hook and install the first hook on the sidewall as described above with the lip portion. As shown in FIG. 47A, thebarrier sheet530 is wrapped around theouter leg118 and secured to the sidewall beneath the first hook.

As shown in FIGS. 48-49, yet another embodiment of thetool182 includes ahandle member184 having acurvilinear surface grip185, asurface member552, a mountingblock554 having alip portion556 and ablade186. As just described, the lip portion engages the second hook, while the blade pushes the strip, and first hook, against theouter leg118. The surface member is preferably made of plastic, such as Delrin, so that it slides easily along the edge of the panel without damaging or tearing the fabric. This embodiment could also employ a second blade member as just described. It should also be understood that alternative embodiments, such as a simple putty knife, also can be used to engage the second hook, stretch the fabric and dispose the first hook on the outer leg of the edge portion.

The strip and hook arrangement disclosed herein is ideally suited for attaching fabric to a wall panel. For example, if the fabric were to become stained, worn or torn, an installer can remove the fabric quickly and easily by using a tool in the opposite manner as described above to disengage the first hook from the outer leg on the sidewall member. Moreover, the fabric can be removed while the panel is connected to adjacent panels if using a tool that can be inserted into the gap between the panels to engage the second hook member. This provides significant advantages over the prior art fabric attachments, which were either permanently secured to the panel or were retained by an elastic band running around the periphery of the panel. In either configuration, the panel had to be disconnected from the adjacent panels so as to access and remove the band or to remove the adhesive.

It should also be understood by one skilled in the art that the strip and hook fabric attachment device can also be used to secure fabric to objects besides wall panels, such as chairs, cabinets, etc. All that is needed is an edge on which to secure the hook member. Thus, the attachment of the fabric to the wall panel as described above is meant to be illustrative rather than limiting.

The lower horizontal frame member, shown in FIGS. 12,14 and58, includes a mountingstrip190 and abracket200 mounted to theouter surface66 of the lower core member. As shown in FIG. 14, theouter surface66 preferably extends below the end portions of the sidewalls. Theside surface67 of the portion of the lower core member extending below the leg portion of the sidewall member is stepped inward to permit the hook member on the strip to be installed on the outer leg. Thegroove33 runs along the outer surface of the core member.

Thebracket200 includesseveral tab members202 which are adapted to engage and support apower distribution server220, including an electrical power harnesses222, as shown in FIGS. 2 and 59. Referring to FIGS. 12 and 13, thetab members202form slots203 that receive bracket hooks560 extending upwardly from the power distribution server as shown in FIG.59. In operation, theharness222 is installed by sliding the bracket hooks560 into theslots203 until the end of thebracket560 passes a resilient locking tab578 which springs downwardly to releasably secure theharness222 on thebracket200. When the wall panel is particularly long, the bracket may also includestabilizer brackets570 that extend downwardly from the bracket and include two arms that engage the harness.

Referring to FIGS. 25-27, the harness includes areceptacle bracket566, aspring tab572 and a plurality of module bracket hooks574. A plurality ofreceptacle modules226 are secured to the harness by engaging the bracket hooks574 with mountinglugs564 disposed on the module. Eachmodule226 is electrically connected to theharness222 at one of a fourreceptacle ports576. Similarly,conduit276 from an outlet box installed in the panel, as described below, preferably includes a connector that can electrically engage one of the receptacle ports in place of a receptacle module. For a complete description of the power distribution server, including the power harnesses, one is directed to U.S. Pat. No. 5,013,252, issued to Neinhuis et al. on May 7, 1991, the disclosure of which is hereby incorporated by reference. The harness also includeselectrical connector ports224 positioned at the end of the harness and which provide a means for electrically connecting adjacent panels, such that a first panel receives power from a second panel. A commercially available harness, Model No. 225409, is sold by PENT Assemblies of Kendallville, Ind. FIGS. 26A-C show various configurations of panels electrically interconnected. In this way, an entire system of panels can be electrically connected and provide power to users at individual work spaces.

Referring to FIG. 14, the mountingstrip190 is disposed between thebracket200 and thecore member32. The mountingstrip190 has a pair ofelongated grooves194 running longitudinally along the edges of the mountingstrip190. The mounting strip supports abase cover230. Thebase cover230 includes a pair ofside walls232 and abottom wall234, as shown in FIGS. 14 and 15. Theside walls232 andbottom wall234 are hinged along the longitudinal length of the base cover, preferably by using aflexible hinge material236. The cover members can also be mechanically hinged. The upper portion of each wall includes abeaded flange238 that is disposed in thegroove194 in the mounting strip. When mounted on the mounting strip, thebase cover230 forms and defines a horizontal channel for storing and protecting cables and wires beneath the panel. The lower horizontal channel also provides a concealed passage way for the cables and wires as they pass from one panel to the next.

Referring to FIG. 2, thebottom wall234 of the base cover includes aslot240 at each end which is adapted to receive asupport leg250 extending down from thevertical frame members14, as explained below. Theside walls232 extend between the lower edge of the wall panel and the floor and includeopenings242 adapted to allow a user to access outlets in themodules226 secured to the power distribution server, which is mounted to the bottom of the lower frame member. Each end of theside wall232 on the base cover includes aflexible strip244 that extends outwardly from the end of the panel. When two panels are installed end-to-end, the opposingflexible strips244 overlap and conceal the gap between the panels.

Referring to FIGS. 2 and 15, the wall panel is supported on and spaced apart from the floor by asupport leg250 attached to eachvertical frame member14. Asupport bracket260 is mounted to the bottom of eachcore member28 on theinner surface48 of the core member. Thebracket260 is mounted in thespace106 provided between the end of the lower core member and the bottom end of the vertical core member, as shown in FIG.12. Thebracket260 includes aU-shaped sleeve portion262 and a pair offlanges264. Theflanges264 are fastened to the inner surface of thecore member28 such that thesleeve portion262 forms anopening266 with the surface of the core member.

Thesupport leg250 includes ashaft252 having ashoulder254 and afoot256. An upper portion of the shaft is received in theopening266 formed by the support bracket and core member until theshoulder254 of the shaft engages the bottom of the260 bracket. The bottom of theshaft252 is threaded and threadably engages thefoot member256 whereby the height of the wall panel can be adjusted by rotating thefoot256 relative to theshaft252.

In a preferred embodiment, anoutlet box270 is installed inside the wall panel frame between the upper andlower frame members16,18. As shown in FIGS. 8 and 11, theoutlet box270 is first bolted to aplate member272, preferably a piece of hardboard. Theplate member272 is adhesively bonded to theinner surface122 of one of the wall members. The opposite wall member has anopening274 aligned with theoutlet box270 so as to allow the user access to the box. Anoutlet cover275 can be installed over the opening. The outlet box is electrically connected to the power distribution server with anelectrical conduit276 that is disposed in thevertical channel108, as described above. Outlets, which are not shown, are installed in the outlet box. It should be understood that the same or similar box can be installed to provide access to data and communication wiring and cables. The outlet box also can be field installed by cutting a hole in one of the thin sheets, the barrier sheet and the wall member.

The wall panels can be connected to form a system of panels that defines and divides large office spaces into work spaces. For example, the wall panels can be connected end-to-end in a simple linear arrangement as shown in FIGS. 19 and 20. In such an arrangement, the panels are positioned adjacent to each other such that opposingouter surfaces80 of the hanger brackets are in a proximal relationship. Anupper draw block280 is provided which has a downwardly facing V-shapeddraw surface282 defined by fourwedge members284, as shown in FIGS. 28-30. Theupper draw block280 includes amiddle portion286 that has ahole288. Similarly, alower draw block290 has an upwardly facing V-shapeddraw surface292 defined by fourwedge members294. Adraw rod296 connects the two draw blocks280,290.

Referring to FIGS. 19-20, theupper draw block280 is positioned such that thewedge members284 engage thetop edge298 of the hanger bracket on the adjacent panels by inserting thewedge members284 into the inwardly facingchannels72. Themiddle portion286 of the draw block is disposed in the space formed between the outwardly facingchannels300, which formed by the inner legs of the channel and the bridge portion.

Similarly, thelower draw block290 is inserted into the bottom end of thechannels72 such that thewedge members294 engage thebottom edge302 of thehanger bracket70 and the middle portion is received in the space formed by thechannels300. Thedraw rod296 is rotatably connected to the lower draw block and threadably engages the upper draw block. The draw rod is disposed in the space formed by the two outwardly facingchannels300 of the opposing hanger brackets as shown in FIGS. 32-33. When rotated, the draw rod threadably engages the upper draw block, pulling it closer to the lower draw block. As the draw rod is tightened, the draw surfaces282,292 of the draw blocks operably engage theends298,302 of the hanger brackets and pull the hanger brackets together. In an alternative embodiment shown in FIG. 29, the draw blocks include aflat surface304 between thewedge members306. When drawn together, the ends of the hanger brackets engage theflat surface304.

As shown in FIG. 30, one embodiment of the draw blocks includes alanding308 and atang member310 extending from the landing on one side of theopening288. This configuration facilitates the installation of the draw blocks and draw rod. In particular, the installer can rest theland portion308 of the upper draw block on thebridge portion74 of one of the hanger brackets, while thetang member310 is disposed in thechannel300 to align the draw block with the hanger bracket. In this way, the connector assembly, i.e., the draw rod and two draw blocks, can be positioned and retained by a first panel as the second wall panel is moved into place next to the first panel. Thedraw rod296 and blocks280,290 can then be lifted up and aligned with thechannels72 on the ends of both panels. Thedraw rod296 is then tightened as explained above so as to connect the two panels.

As shown in FIGS. 4-5 and31-33, two or more panels can also be connected in a perpendicular relationship. In such a configuration, acorner post320 is installed between adjacent panels. Thecorner post320 includes a substantially square,elongated tube322 and an upper andlower plate324,326 mounted inside each end of the tube, preferably by welding. Eachplate324,326 includes a threadedhole328 in the middle of the plate. A pair of inwardly facingchannels330 are formed longitudinally along each side of thetube322. The inwardly facingchannels330 also form an outwardly facing channel between them. Preferably, thetube322 is made from two overlapping C-shapedpieces332,334 welded together as shown in FIGS. 32-33.

Referring to FIGS. 4 and 5, each corner of the tube includes an outwardly facinggroove336 that runs longitudinally along the length of thetube322. As shown in FIGS. 32 and 33, thegroove336 is preferably formed by the outer legs of thechannels330, which are joined at the corners of the tube at approximately 90°.

As shown in FIG. 31, each wall panel is connected to the corner post in the same way as described above. An upper andlower draw block280,290 engage the top and bottom edge of the twochannels330 on the side of the tube and the twochannels72 of the hanger bracket mounted on the side of the wall panel being connected. Thedraw rod296, connecting the draw blocks, is tightened to pull the draw blocks together and to pull the wall panel towards the corner post so that the hanger bracket engages the side of the tube. It should be understood that one, two, three or four wall panels can be connected to the corner post at any time depending on the desired configuration.

As shown in FIGS. 5 and 33, when two wall panels are connected to thecorner post320 at 90°, the opposing two sides of the corner post are concealed by an V-shapedcover member340 adapted to be disposed on the adjacent, perpendicular sides of the corner post. Thecover member340 includes a beadedportion342 running longitudinally along the side edges344 of the cover. The beadedportions342 are adapted to engage the outwardly facinggroove336 formed along each corner of thetube322. The beadedportion342 extends diagonally inward from the cover at approximately 45°. Thecover member340 includes an outer layer of fabric346 that matches the thin sheet of fabric disposed on the adjacent wall panels.

When two wall panels are arranged in a 180° relationship on opposite sides of the tube, aflat cover member348 can be installed on one or both of the exposed sides of thetube322 as shown in FIGS. 4 and 32. Theflat cover member348 includes diagonally facing beadedportions350 running longitudinally along its length.

Referring to FIG. 4, asupport member352 is attached to the bottom of thetube member322. Thesupport member352 includes abase portion354, aleg356 and afoot358. Thebase portion354 is attached to thelower plate326 secured in the bottom end of thetube322. Abase cover360 is installed on thesupport member352 to conceal thesupport member352 and the space below the panel. Thebase cover360 extends between thebase portion354 and thefoot358. Thefoot358 includes abottom member362 and a pair ofcylindrical lug members364 positioned on opposite sides of thebottom member362. Thebase portion354 includes slottedportions366 positioned on the same side as thelug members364.Tele base cover360 includes upwardly facingtab members368 that engage the slottedportions366 and a pair offlange members368 that engage the lug members. Theleg356 is preferably a thin shaft that allows cables and wires to pass between theleg356 andbase cover360 as they are passed between adjacent panels. In this way, thecover360 forms part of the lower horizontal channel. It should be understood that the support does not engage the floor, but rather is provided to support the base cover member, which conceals and protects wires in the lower channel.

When two panels are attached to a corner post at 90°, the support does not include a foot. In this arrangement, the support includes abase portion372 and aleg374 as shown in FIG.5. Thebase cover376, shown in FIG. 30, includes twowalls378, abase plate380 and aguide plate382. Thebase portion372 includes aslot384 and twotab members386 on two sides of the base portion. Alip portion388 is positioned on the top of eachbase cover wall378. When installed, thelip portion388 is inserted into theslot384 as the twotab members386 engage the bottom of thelip388 to releasably secure thebase cover376 to thebase portion372. Theguide plate382 extends between thewalls378 and lies parallel to thebase plate380. Theguide plate382 includes aslot384 adapted to receive theleg374 of the support. Thebase plate380 includes anopening390 that is adapted to receive an end of the leg, which includes alug392. In this way, the base cover is supported by the support base portion and is stabilized by the leg.

As shown in FIGS. 4,5 and7, thecorner post320 also includes acap assembly400 adapted to span the gap between adjacenttop caps110 installed on top of each wall panel. Preferably, thecap assembly400 is plastic. FIGS. 4,5 and7 show the cap assembly which includes apost member420. Thepost member420 has a threadedend404 that threadably engages the threadedhole328 in theupper plate324 secured in the end of thetube322. Thecap400 also includes abase member406, alock member408 and acover member410. Thebase member406 includes astep portion412 on each side of the base and aprimary post member414 extending upwardly from the middle of each side of thetop surface416 of the base member. Eachprimary post member414 includes ashaft portion418 and ahead portion420. Eachprimary post member414 is slotted so as to make the head and shaft portions flexible and resilient. Twosecondary post members424, positioned on opposite sides of the primary post member, extend upwardly from eachstep portion412 of the base member. Acylindrical sleeve portion426 extends downwardly from the bottom of thebase member406. Thesleeve portion426 is adapted to receive the top of the post member402, so that the post member supports and rotatably engages thebase member406. The post member402 allows the height of the corner post cap to be adjusted as it threadably engages theupper plate324 in thetube322. In addition, thepost member420 is slender so that cables wires and the like can be disposed around the post member as they pass from the upperhorizontal channel88 of one panel to the next.

Thelock member408 is rectangular and includesopenings428 adapted to receive thesecondary post members424. Thelock member408 also includes fouropenings430 adapted to receive the head and shaft of theprimary post member414. A shoulder is disposed inside each opening so that when the primary post member is inserted into the opening, the head extends through the plate member and engages the shoulder to thereby releasably secure the plate member to the base member. Thecover member410 is releasably secured to the top of thelock member408.

Referring to FIGS. 3-7, alight seal432 is provided to connect the top cap on the wall panel with the corner post cap. Thelight seal432 includes a mountingflange434 having two holes: a slottedhole436 and around hole438. Theholes436,438 are adapted to receive thesecondary post members424. The mountingflange434 also includes a semicircular cut-awayportion440. Thelight seal432 is installed on thebase member406 by inserting thesecondary post members424 into theopenings436,438 in the mountingflange434. The bottom of the mountingflange434 engages thestep portion412 so that the top of the flange lies flush with the top surface of thebase member406. The cut-awayportion440 is disposed around theprimary post member414. Thelock member408 is installed on thebase member406 so as to releasably secure thelight seal432 to thebase member406.

Thelight seal432 includes aninsert portion442 with arib444 defining an end of theinsert portion442. Theinsert portion442 is adapted to be received in the open end of thetop cap110 mounted on each wall panel. Thelight seal432 also includes downwardly extendinglegs446. The legs extend downwardly between the upwardly extendingsidewall members36 of the adjacent upper frame member and thecover member340,348 disposed on the side of the corner post so as to prevent light from penetrating the gap between the two members. Eachleg446 also includes abeveled edge448 that mates with an opposing edge of an adjacent leg which two light seals are installed at 90° to each other. The light seal is preferably made of plastic and the legs can be trimmed to the proper length before installation.

Referring to FIG. 6, alight seal450 is provided to bridge the gap between the top caps on two panels placed end-to-end and connected to each other. In this embodiment, thelight seal450 includes twoinsert portions452 facing away from each other and that are separated by arib454. Theinsert portions454 are received in each wall paneltop cap110. Therib454 provides a smooth and continuous transition between thetop caps110. Thelegs456 of the light seal extend downwardly and conceal the gap between the adjacent upwardly extending sidewalls of the two panels.

Referring to FIGS.36 and38-40, a connector is provided to attach a shorter wall panel to a taller wall panel. In this configuration, anupper draw block460 includes a pair ofwedge members462 on one side and a pair ofhook members464 on the opposite side. Thehook members464 are adapted to engage theslots86 in thehanger bracket70 attached to the side of the taller wall panel. Thewedge members462 engage the top298 of thehanger bracket channels72 on the shorter wall panel as described above. To connect the panels, thedraw rod296 is tightened to pull the two wall panels together. Alight seal470 is installed on the shorter panel so that itslegs472 are disposed on either side of theupper draw block460. Aninsert portion474 of thelight seal470 is received in thetop cap110 attached to the top of the shorter panel. The end of thelight seal470 is defined by aflat surface478 which extends downwardly from arib476. Theflat surface478 abuts thehanger bracket70 on the taller panel.

Referring to FIGS. 3,36,39 and57, a pair ofend cover brackets480 are installed on the exposed end of any wall panel which is not connected to another wall panel or a corner post. Theend cover bracket480 includes a pair of outwardly facinggrooves482 running along opposite side edges of the bracket. Aend cover484 is attached to thebracket480 on the end of the panel to provide a finished appearance. Thecover484 comprises a channel with atop wall486 closing the upper end of the channel. The end cover also includes a pair ofU-shaped brackets488 mounted inside the channel. The brackets each include inwardly facingflanges490 which are inserted into thegrooves482 in the end cover bracket mounted to the end of the wall panel. A light seal can be installed between the end cover and the top cap of the wall panel, as shown in FIGS. 3 and 36.

When installing a shorter panel adjacent to a taller panel, anend cover bracket480 is mounted to the exposed portion of the hanger bracket and wall panel end extending above the shorter panel. Ashort end cover485, shown in FIGS. 36 and 40, is mounted on the bracket so that the exposed upper portion of the taller wall panel is covered. Alight seal450 is then installed between the end cover and the top cap on the taller wall panel.

Referring to FIGS. 41-42, the wall panel also can be attached to apermanent wall494. In this arrangement, a mountingplate496 is disposed inside a channel-shapedcover498 having atop wall499, similar to an end cover. Ahanger bracket70, thecover498 and mountingplate496 are mounted on thepermanent wall494 with a plurality of fasteners. The wall panel is connected to the hanger bracket as described above, with alight scale450 being inserted between the cover and the top cap of the adjacent panel.

The construction of the frame members and panel, as described above, is ideally suited for improved manufacturability of the wall panel. In particular, the method for making each vertical frame member includes providing acore member28, ahanger bracket70 and a pair ofsidewall members34, each having anedge portion40 with anouter leg118 having an outer surface. Thehanger bracket70 is attached to theouter surface50 of the core member as discussed above.

Referring to FIGS. 50-51, thecore member28 andhanger bracket70 are placed in afixture500, which has afirst surface502 spaced apart from a second andthird surface504,505. Thefixture500 is rotatably attached tosupports506 at each end of thefixture500. In this way, fixture surfaces can be provided on opposite sides of the same fixture for different frame members. The fixture is simply rotated so that the surfaces to be employed are accessible to the assembler.

As illustrated in FIG. 51, thecore member28 andhanger bracket70 are positioned in the fixture such that an outer surface of the hanger bracket engages thefirst surface502. Thesidewalls34 are then inserted into thefixture500 on opposite sides of the core member. The ends of the sidewalls and the ends of the core member are positioned relative to each other in the fixture using a locator pin as theouter leg118 of the edge portions of the two sidewalls engage the second andthird surfaces504,505 of the fixture respectively. The core member, hanger bracket and sidewalls are clamped together in the fixture using a plurality ofclamps508. The sidewalls are then attached to the core member with a plurality of fasteners, preferably staples. Alternatively, the sidewalls can also be bonded to the core member using a suitable adhesive, or bonded and mechanically fastened.

It should also be understood by one skilled in the art, that various aspects of the assembly process can be automated. For example, the hand clamps shown in FIG. 51 can be replaced with pneumatically controlled clamps. Similarly, the fastening process can be automated, whereby the application of adhesive and stapling is done automatically.

By using a fixture as just described, the distance between the outer surface of the hanger bracket and the outer leg of each sidewall can be maintained as a relative constant with relatively tight tolerances. Thus, when two panels are installed end-to-end, the gap between adjacent opposing sidewalls will be maintained with tight tolerances so as to provide a uniform appearance when viewing a system of interconnected wall panels. In essence, the gap at each joint between adjacent panels is maintained as a relative constant. Moreover, this method of manufacture ensures that the slotted portion of the hanger bracket is always maintained a constant distance from theouter leg118 of the sidewall edge portion. Thus, the user is ensured that components can be consistently installed on the hanger bracket without having to force the component past a protruding sidewall.

Another advantage of this method is realized when different thickness fabrics are installed on the panel. Typically, when a thicker fabric is installed on one panel, the fabric fills more of the gap between connected panels, and can therefore interfere with the installation of components on the hanger brackets, as well as creating a displeasing appearance as between adjacent joints. With the current construction, the distance between the first and second and third surfaces in the fixture can be altered to provide more or less distance between them so as to accommodate thicker or thinner fabrics respectively.

Referring to FIG. 52, ascanner600 or caliper can be used to measure the thickness of thefabric130 being installed and provide that data to a computer. Thecomputer602 employs logic and actuates aservo motor604 that changes the relative distance between the first and second and third surfaces so as to provide a uniform gap between panels once the fabric is installed. It should be understood that actuators could alternatively be used to adjust the second and third surfaces relative to the first surface. In this way, the second surface could be spaced a greater distance from the first surface than the third surface is from the first surface so as to accommodate two different thickness fabrics on each side of the panel. For example, it may bc desirable to employ a heavy thick fabric on the outside wall of a panel system forming a walkway which experiences a lot of abuse, while providing a thinner fabric, for reasons of color selection etc., on the inside wall of the system forming the workspace.

Another advantage is realized by using a wooden core member in each of the frame members in that the sidewalls can be attached extremely fast and inexpensively with staples, rather than by expensive welding or mechanical screw and bolt type fasteners.

The upper and lower frame members are made in a similar manner, except that thefirst fixture surface620 engages the core member rather than the hanger bracket as shown in FIGS. 53-54. The sidewall members are installed so that theouter legs118 engage the second and third fixture surfaces622,623 respectively. The bracket and mounting strip are installed on the outer surface of the lower core member with mechanical fasteners. Thegroove33 positioned along the bottom of the bottom core member allows space for ends of a tool locator which positions the bracket and mounting strip relative to the bottom of the panel.

A method is also provided to assemble the wall panel. The method includes providing a plurality offixtures512 havinghorizontal surfaces514 andvertical surfaces516. Thefixtures512 are arranged in a rectangular configuration on abed522, as shown in FIGS. 55-56. Apedestal support524 extends upwardly from the bed in the middle of the fixture arrangement. Each fixture is provided with aclamp520. Adhesive is applied to the inner surface of one of the wall members around its edge. The wall member is then placed on thehorizontal surface514 of the fixtures with the inner surface facing upward. Thepedestal support524 supports the outer surface of the wall member. The four frame members, i.e., thevertical frame members14 and the upper andlower frame members16,18, are placed in the fixtures such that thesidewalls34,36,38 of each frame engage the fixture surfaces oriented around the panel. The sidewalls of the upper frame member are pinched together and inserted between the upwardly extendingsidewalls68 of the vertical frame members and then released so that the sidewalls overlap. Similarly, the outwardly extendingsidewalls38 of the lower frame member are overlapped with the exposed core of thevertical frame members550. Thevertical surfaces516 of the fixture are magnetized withmagnets521 to attract and hold the frame members to thevertical surfaces516.

Apartition member140, with adhesive applied to the mountingflange142, is then installed at each end of the panel by bonding the mounting flange to theinner surface122 of the wall member. Theboundary flange144 extends away from the wall member to form thevertical channel108. Because the partition member is preferably made of cardboard, it can be easily installed by bonding rather than be welding or mechanically fastening as would typically be required for metal or wood partitions.

Adhesive is applied to both sides of thehoneycomb filler member150 and it is disposed inside the frame on theinner surface122 of thewall member120. Thefiller member150 substantially fills the space between the upper and lower frame members and between the two partition members. In a preferred embodiment anoutlet box270 is mounted to a hardboard base plate with a fastener. The base plate is adhesively bonded to theinner surface122 of the wall member. One of a portion of the partition member or filler material is removed to allow the outlet box to be installed on the inside of the frame. The outlet box can be installed between the partition members, or such that one side of the box is aligned with the partition member to thereby provide a wall defining the inner surface of the vertical channel. Theconduit276 connecting the outlet box to the power system is disposed in the vertical channel and extends through the space between the bottom core member and the vertical core member.

Adhesive is applied around the edges of theinner surface122 of the second wall member. Thewall member120 is positioned in the recess formed on a second side of the frame by the edge portions of the sidewalls. Wien an outlet box has been installed on the first wall member, a hole is cut in the second wall member so as to be substantially aligned with the outlet box once the second wall member is installed. The two wall members and frame are clamped together and to the fixtures. A staple gun, preferably a dualaction staple gun640 accessing both sides of the panel simultaneously, as shown in FIG. 56, is used to mechanically fasten the two wall members to the four frame members, and in particular, to staple through the wall member and sidewall member and into the core member. Fasteners are also installed in the overlapping portions of the upwardly extending vertical sidewalls, the sidewalls of the upper frame member and the wall member, as described above. As described above, it should be understood that various aspects of this assembly process could be automated. For example, the clamping could be pneumatically controlled, and the positioning of the wall members, filler member, partition members and frame members could be automated.

Because the core members are preferably made out of wood, the wall members can be easily and cheaply secured to the frame. This construction avoids the use of expensive and time consuming welding operations and/or the use of expensive screw and bolt type fasteners.

The support leg is installed by press fitting the upper portion of the leg into the opening between the bracket and core member. The foot member is attached to the leg member.

The barrier sheet is disposed on both sides of the wall panel, and is either adhesively or mechanically attached to the wall member or the frame members. Alternatively, the barrier sheet can be wrapped around the edge portions of the sidewall members underneath the decorative sheet, which secures the barrier sheet to the wall panel, as shown in FIG.47A.

Next, the decorative sheets are installed by disposing a sheet on each side of the panel and attaching the strip to the edge portion of each side wall as described above, including the steps of tucking the excess fabric corner patch located at the corners into the edge portion channel and inserting a flexible corner block into each corner to secure the fabric in the channel.

It should be understood that all of the aforementioned steps of manufacture can be interchanged without departing from the spirit and scope of the invention. As such, it is intended that the foregoing order of steps be regarded as illustrative rather than limiting.

Additional steps can be included to accessorize the panel. For example, a top cap typically is installed on each panel. In addition, the power distribution system can be installed by attaching the power distribution server, including the receptacle modules and harnesses, to the bracket on the bottom of the lower frame member. In addition, the base cover can be installed on the mounting strip to conceal and protect the power distribution system. The base cover is installed by securing the two side walls to the mounting strip attached to the bottom of the lower frame member.

When assembled in a system of panels, the horizontal channel formed along the top and bottom of the panels provides the user with an ideal and easy to access space for storing and routing cables and wires, such as communication and data lines. Moreover, the vertical channels in each panel allow the user to easily rout wires and cables from the top of the panel to the bottom. In addition, the vertical channels provide a ready-made space for routing electrical conduit from the outlet mounted in the panel to the base of the panel and the attached power distribution system.

Although the present invention has been described with reference to preferred embodiments, those skilled in the art will recognize that changes may be made in form and detail without departing from the spirit and scope of the invention. As such, it is intended that the foregoing detailed description be regarded as illustrative rather than limiting and that it is the appended claims, including all equivalents thereof, which are intended to define the scope of the invention.

Claims (20)

We claim:

1. A method for reconfiguring a system of wall panels comprising:

providing at least one substantially square vertical corner post comprising four sides each terminating in an upper and lower edge, four corners formed at the junctures of the respective sides, and an outwardly facing groove running vertically along each of said corners;

providing a plurality of wall panels, each of said wall panels having a vertically extending hanger bracket disposed along at least one side thereof, each of said hanger brackets terminating in an upper and lower edge;

providing a plurality of pairs of upper and lower draw members, each of said lower draw members engaging one of said lower edges of said corner post and a lower edge of one of said hanger brackets, each of said upper draw members engaging one of said upper edges of said corner post and one of said upper edge and one of said slots of said hanger brackets;

connecting each of said pairs of upper and lower draw members with a draw rod so as to connect each of said plurality of wall panels to said corner post;

removing at least one of said plurality of wall panels so as to expose at least one of said sides of said corner post;

providing a cover comprising at least a pair of edges;

covering said at least one exposed side of said corner post with said cover by releasably engaging a pair of said grooves on said corner post with said edges of said cover.

2. The method of claim1 further comprising removing at least one of said plurality of wall panels so as to expose at least one of said sides of said corner post, and providing at least one new wall panel having a different height than said at least one wall panel being removed, said at least one new wall panel having a vertically extending hanger bracket disposed along at least one side thereof, each of said hanger brackets having an upper and lower edge and a plurality of slots, connecting said at least one new wall panel to said corner post along said at least one exposed side of said corner post with a pair of draw members and a draw rod extending therebetween.

3. The method of claim1 wherein said plurality of wall panels comprises four wall panels, each of said wall panels connected to one of said sides of said corner post.

4. The method of claim1 wherein said removing said at least one wall panel comprises removing one wall panel so as to expose one side of said corner post, and wherein said cover is substantially flat, and wherein said covering said-exposed side comprises releasably engaging the grooves running along said corners bounding said exposed side of said corner post with said edges of said substantially flat cover.

5. The method of claim1 wherein said removing at least one panel comprises removing two panels arranged in a perpendicular relationship to each other so as to expose two adjacent sides of said corner post, and wherein said cover comprises two substantially flat portions connected in a substantially perpendicular relationship, and wherein said covering at least one exposed side of said corner post comprises releasably engaging the grooves running along opposite corners of said corner post with said edges of said cover.

6. The method of claim1 wherein said each of said hanger brackets comprises a plurality of slots spaced vertically along said hanger bracket.

7. The method of claim1 wherein said each side of said corner post comprises an outwardly facing channel formed along a length of each of said sides of said corner post, wherein at least a portion of said draw rod is disposed in said channel, and wherein said upper and lower draw members each comprise at least a pair of draw surfaces, wherein each of said at least said pair of said draw surfaces on said upper draw member engages said upper edge of one of said sides on opposite sides of said channel formed therealong, and wherein each of said at least said pair of said draw surfaces on said lower draw member engages said lower edge of one of said sides on opposite sides of said channel formed therealong.

8. The method of claim7 wherein each of said upper and lower draw members comprises four draw surfaces, wherein two of said draw surfaces engage one of said upper and lower edge of said side of said corner post and wherein the other two of said draw surfaces engage one of the upper and lower edges of said adjacent hanger bracket.

9. The method of claim1 wherein said edge of said cover comprises a beaded portion.

10. A method for reconfiguring a system of wall panels comprising:

providing at least one substantially square vertical corner post comprising an elongated tube having a plurality of sides each terminating in an upper and lower edge and an outwardly facing channel formed along a length of said tube;

providing a plurality of wall panels, each of said wall panels having an vertically extending end portion terminating in an upper and lower edge;

providing a plurality of pairs of upper and lower draw members, each of said lower draw members engaging one of said lower edges of said corner post and a lower edge of one of said wall panels, each of said upper draw members engaging one of said upper edges of said corner post and one of said upper edge of said wall panel, wherein said upper draw block in each of said pairs overlies said lower draw block in said pair;

connecting each of said pairs of upper and lower draw members with a draw rod, wherein at least a portion of said draw rod is disposed in said channel;

removing at least one of said plurality of wall panels so as to expose at least one of said sides of said corner post;

providing a cover;

covering said at least one exposed side of said corner post with said cover.

11. The method of claim10 wherein said end portion of said wall panel comprises a longitudinally extending outwardly facing channel, and wherein at least a portion of said draw rod is disposed in said channel.

12. The method of claim11 wherein said wall panel comprises a vertically extending hanger bracket extending along each vertical end of said wall panel, wherein said hanger bracket defines said channel formed on said wall panel.

13. The method of claim10 wherein said removing said at least one wall panel comprises removing one wall panel so as to expose one side of said corner post, and wherein said cover is substantially flat, and wherein said covering said at least one exposed side of said corner post comprises covering said one exposed side with said substantially flat cover.

14. The method of claim10 wherein said removing at least one panel comprises removing two panels arranged in a perpendicular relationship to each other so as to expose two adjacent sides of said corner post, and wherein said cover comprises two substantially flat portions connected in a substantially perpendicular relationship along one side of said flat portions, and wherein said covering said at least one exposed side of said corner post comprises covering said two adjacent exposed sides of said corner post with said substantially flat portions respectively.

15. The method of claim10 wherein each of said upper and lower draw members comprises at least a pair of draw surfaces, wherein said at least said pair of said draw surfaces on said upper draw member engages said upper edge of one of said sides on opposite sides of said channel formed therealong, and wherein each of said at least said pair of said draw surfaces on said lower draw member engages said lower edge of one of said sides on opposite sides of said channel formed therealong.

16. The method of claim15 wherein each of said upper and lower draw members comprises four draw surfaces, wherein two of said draw surfaces engage one of said upper and lower edge of said side of said corner post and wherein the other two of said draw surfaces engage one of the upper and lower edges of said end portion of said wall panel.

17. A method for reconfiguring a system of wall panels comprising:

providing at least one substantially square vertical corner post comprising an elongated tube having a plurality of sides, each of said sides comprising a pair of inwardly facing channels formed along a length of said tube, each of said channels terminating in an upper and lower edge;

providing a plurality of wall panels, each of said wall panels having an vertically extending end portion terminating in an upper and lower edge;

providing a plurality of pairs of upper and lower draw members, wherein each of said upper draw members having at least a pair of draw surfaces engaging said upper edges of said channels formed along one of said sides of said corner post and at least one opposite draw surface engaging said upper edge of said wall panel end portion, wherein each of said lower draw members having at least a pair of draw surfaces engaging said lower edges of said channels formed along one of said sides of said corner post and at least one opposite draw surface engaging said lower edge of said wall panel end portion, wherein said upper draw block in each of said pairs overlies said lower draw block in said pair;

connecting each of said pairs of upper and lower draw members with a draw rod;

removing at least one of said plurality of wall panels so as to expose at least one of said sides of said corner post;

providing a cover;

covering said at least one exposed side of said corner post with said cover.

18. The method of claim17 wherein said end portion of said wall panel comprises a pair of inwardly facing channels each terminating in an upper and lower edge, and wherein said opposite draw surface of said upper and lower draw members comprises a pair of opposite draw surfaces, wherein said pair of said opposite draw surfaces of said upper and lower draw members engages said upper and lower edges of said pair of wall panel channels respectively.

19. The method of claim17 wherein said removing said at least one wall panel comprises removing one wall panel so as to expose one side of said corner post, and wherein said cover is substantially flat, and wherein said covering said at least one exposed side comprises covering said one exposed side with said substantially flat cover.

20. The method of claim17 wherein said removing at least one panel comprises removing two panels arranged in a perpendicular relationship to each other so as to expose two adjacent sides of said corner post, and wherein said cover comprises two substantially flat portions connected in a substantially perpendicular relationship, and wherein said covering at least one exposed side of said corner post comprises covering said exposed adjacent sides of said corner post with said substantially flat portions respectively.

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